Spring core with integrated cushioning layer
A spring core is provided that includes a plurality of coil springs having an upper portion and a lower portion that collectively define an interior cavity. The spring core further includes a continuous upper fabric layer that covers each coil spring and defines a recess in the interior cavity of each coil spring. A cushioning layer is positioned atop the continuous upper fabric layer and extends into the recess in the interior cavity of each coil spring. A mattress assembly is further provided that includes the spring core, an upper body supporting layer, and a lower foundation layer. Methods of producing a spring core are further provided.
1. A spring core, comprising:
a plurality of coil springs, each coil spring having an upper portion and a lower portion, the upper portion and the lower portion collectively defining an interior cavity of each coil spring;
a continuous upper fabric layer covering the upper portion of each coil spring and extending into the interior cavity to define a recess in the interior cavity of each coil spring;
a cushioning layer positioned atop the continuous upper fabric layer and extending into the recess, said cushioning layer having a lower surface adjacent to the plurality of coil springs and the continuous upper fabric layer wherein the lower surface is free of foam molded recesses and engages said continuous upper fabric layer, said cushioning layer defined by a precursor that is poured on to the continuous upper fabric layer wherein said cushioning layer forms within the recess of each of said plurality of coil springs and between springs, and said cushioning layer being bonded to the continuous upper fabric layer when cured; and,
a second continuous lower fabric layer covering the lower portion of each coil spring, said second continuous lower fabric layer connected to said continuous upper fabric layer around each coil and extend into the interior cavity of each coil spring to define the recess.
2. The spring core of claim 1 , wherein the continuous upper fabric layer is connected to the second continuous lower fabric layer around each coil spring such that the continuous upper fabric layer and the second continuous lower fabric layer collectively form a fabric pocket encasing each coil spring.
3. The spring core of claim 1 , wherein each coil spring has a height, and wherein each recess extends into the interior cavity of each coil spring to about half of the height of each coil spring.
4. The spring core of claim 1 , wherein the cushioning layer has a substantially planar top surface.
5. The spring core of claim 1 , wherein the continuous upper fabric layer is comprised of a non-woven textile.
6. The spring core of claim 1 , wherein the continuous upper fabric layer, the second continuous lower fabric layer, or both are comprised of a non-woven textile.
7. The spring core of claim 1 , wherein the cushioning layer is comprised of a visco-elastic foam.
8. The spring core of claim 1 , wherein the cushioning layer is comprised of a gel.
9. The spring core of claim 1 , wherein the cushioning layer is comprised of a latex.
10. The spring core of claim 1 , wherein the continuous upper fabric layer further defines intermediate recesses between each of the plurality of coil springs, and wherein the cushioning layer extends into the intermediate recesses.
11. The spring core of claim 1 , wherein the continuous upper fabric layer is connected to the second continuous lower fabric layer between each of the plurality of coil springs to thereby define an intermediate recess between each of the plurality of coil springs, and wherein the cushioning layer extends into the intermediate recess between each of the plurality of coil springs.